Fluid couplings and methods for additive manufacturing thereof

ABSTRACT

A method is provided involving an additive manufacturing system. This method includes a step of forming a first fluid conduit using the additive manufacturing system. The method also includes a step of providing a fluid coupling. The fluid coupling includes the first fluid conduit and a second fluid conduit. The first fluid conduit is connected to and fluidly coupled with the second fluid conduit. The first fluid conduit has a first configuration. The second fluid conduit has a second configuration that is different than the first configuration.

This application claims priority to U.S. Patent Appln. No. 61/991,163filed May 9, 2014.

BACKGROUND OF THE INVENTION

1. Technical Field

This disclosure relates generally to a fluid coupling and, moreparticularly, to connecting conduits of a fluid coupling together aswell as methods for manufacturing the fluid coupling. Such a fluidcoupling may be included in various industrial and consumer equipmentincluding, but not limited to, turbine engines.

2. Background Information

A turbine engine may include a fluid circuit for delivering orcirculating fluid such as fuel, lubricant and/or coolant. Such a fluidcircuit may include a fluid coupling that includes a plurality of fluidconduits connected together. A typical transition between adjacent fluidconduits may be relatively abrupt due to manufacturing constraints. Suchan abrupt transition may create flow disturbances and/or lead toformation of coke where, for example, the fluid flowing within the fluidconduits is jet fuel.

There is a need in the art for improved connections between fluidconduits as well as improved methods for forming conduits of a fluidcoupling.

SUMMARY OF THE DISCLOSURE

According to an aspect of the invention, a method is provided involvingan additive manufacturing system. This method includes a step of forminga first fluid conduit using the additive manufacturing system. Themethod also includes a step of providing a fluid coupling. The fluidcoupling includes the first fluid conduit and a second fluid conduit.The first fluid conduit is connected to and fluidly coupled with thesecond fluid conduit. The first fluid conduit has a first configuration.The second fluid conduit has a second configuration that is differentthan the first configuration.

According to another aspect of the invention, an assembly is providedfor a fluid delivery system. This assembly includes a fluid coupling,which includes a first fluid conduit, a second fluid conduit and acompliant intermediate fluid conduit. The intermediate fluid conduitconnects and fluidly couples the first fluid conduit to the second fluidconduit. The intermediate fluid conduit is formed integral with thefirst and the second fluid conduits.

According to still another aspect of the invention, another assembly isprovided for a fluid delivery system. This assembly includes a fluidcoupling, which includes a first fluid conduit and a second fluidconduit. The first fluid conduit is connected to and fluidly coupledwith the second fluid conduit at a joint. The first fluid conduit isinterlocked with the second fluid conduit at the joint.

The method may include a step of forming the second fluid conduit usingthe additive manufacturing system.

The second fluid conduit may be formed integral with the first fluidconduit.

The first fluid conduit may be connected to and fluidly coupled with thesecond fluid conduit during the forming of the first and the secondfluid conduits.

The method may include a step of fluidly coupling the first fluidconduit to the second fluid conduit after the forming of the first andthe second fluid conduits.

The method may include a step of connecting and fluidly coupling thefirst fluid conduit to the second fluid conduit. The first fluid conduitmay be formed discretely from the second fluid conduit.

A joint between the first fluid conduit and the second fluid conduit mayhave a non-rectangular configuration.

The first fluid conduit may interlock with the second fluid conduit.

The method may include a step of connecting and fluidly coupling thefirst fluid conduit to the second fluid conduit through a compliantintermediate fluid conduit. The intermediate fluid conduit may be formedintegral with the first and the second fluid conduits.

The first fluid conduit may have a cross-section with a first shape. Thesecond fluid conduit may have a cross-section with a second shape thatis different than (or the same as) the first shape. In addition oralternatively, the first fluid conduit may form a first flowpath with afirst cross-sectional area. The second fluid conduit may form a secondflowpath with a second cross-sectional area that is different than (orthe same as) the first cross-sectional area.

The intermediate fluid conduit may be adapted to allow movement betweenthe first and the second fluid conduits.

The intermediate fluid conduit may extend along a substantially straightcenterline.

The intermediate fluid conduit may extend along a curved and/or compoundcenterline.

The first fluid conduit may have a first configuration. The second fluidconduit may have a second configuration that is different than (or thesame as) the first configuration.

The assembly may include a fluid source and a turbine engine component.The turbine engine component may be fluidly coupled to the fluid sourcethrough the fluid coupling.

The first fluid conduit may be formed integral with the second fluidconduit.

The foregoing features and the operation of the invention will becomemore apparent in light of the following description and the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a fluid delivery system configured todeliver fluid to a component.

FIG. 2 is a side sectional illustration of a portion of a turbine enginefuel injector.

FIG. 3 is a cross-sectional illustration of the fuel injector of FIG. 2at a first location.

FIG. 4 is a cross-sectional illustration of the fuel injector of FIG. 2at a second location.

FIGS. 5-12 are partial side illustrations of various alternativeembodiments of a fluid coupling for the fuel injector of FIG. 2.

FIG. 13 is a side cutaway illustration of a geared turbine engine.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a block diagram of a fluid delivery system 20 configured todeliver fluid to a component 22. The fluid delivery system 20 may alsobe configured to receive fluid from the component 22 as illustrated bythe dashed line 24; e.g., circulate the fluid through the component 22.

The component 22 may be configured as or include a heat exchanger, abearing, a gear train, a nozzle (see FIG. 2), a combustor, an augmentoror a diffuser. For ease of description, the component 22 is describedbelow and illustrated in FIG. 2 as nozzle (e.g., a nozzle plate) of agas turbine engine fuel injector. The fluid delivery system 20, however,is not limited to delivering fluid to the exemplary components describedabove. For example, the component 22 may be configured as any fluidreceiving device or system of a turbine engine. Furthermore, the fluiddelivery system 20 may also be configured to deliver the fluid to aplurality of components in serial and/or in parallel, some or all ofwhich may have the same configuration or different configurations.

The fluid may be heat exchange fluid (e.g., liquid and/or gaseouscoolant), and delivered to cool or heat the component 22. The fluid maybe actuator fluid (e.g., hydraulic liquid or compressed air), anddelivered to actuate the component 22. The fluid may be fuel, anddelivered for distribution by or combustion within the component 22. Thefluid delivery system 20, however, is not limited to delivering theexemplary fluids described above.

The fluid delivery system 20 of FIG. 1 includes a fluid pump 26 and afluid source 28; e.g., a reservoir, a tank, a sump or an inlet. Thefluid delivery system 20 also includes a fluid circuit 30 that fluidlycouples the components 22, 26 and 28 together in an open loop, or in aclosed loop as shown by the dashed line 24.

The fluid circuit 30 includes a plurality of fluid couplings 32-34. Eachof the couplings 32-34 includes one or more coupling devices, which forma fluid flowpath through which the fluid may be directed betweenrespective components. Examples of a coupling device include, but arenot limited to, a conduit (e.g., a pipe, hose or duct), a manifold, asplitter, a valve, a regulator, a meter and a filter.

The coupling 32 may extend between and fluidly couples the fluid source28 to the fluid pump 26. The coupling 33 may extend between and fluidlycouples the fluid pump 26 to the component 22. The coupling 34 mayextend between and fluidly couples the component 22 to the fluid source28.

At least one of the couplings 32-34 includes a coupling assembly 36.This coupling assembly 36 forms at least a portion of one of thecouplings 32-34. For ease of description, the coupling assembly 36 isdescribed below and illustrated in FIG. 1 as being included in andforming at least a portion of the coupling 33. However, in otherembodiments, the coupling assembly 36 may alternatively be included inand form at least a portion of one of the other couplings 32 or 34.Furthermore, in some embodiments, the fluid circuit 30 may include aplurality of coupling assemblies, in parallel and/or in serial, thatpartially or completely form one or more of the couplings 32-34.

Referring to FIG. 2, the coupling assembly 36 includes a plurality offluid conduits 38 and 40. Each of these fluid conduits 38 and 40 may beconfigured as a pipe, a hose, a duct or any other generally tubularobject for directing fluid therethrough.

The first fluid conduit 38 may have a generally tubular sidewall 42 thatforms a fluid flowpath 44; e.g., a generally cylindrical fluid flowpath.This fluid flowpath 44 extends along a centerline 46 through the firstfluid conduit 38.

Referring to FIG. 3, the sidewall 42 may have an annular circularcross-sectional geometry. The first fluid conduit 38, however, is notlimited to such a cross-sectional geometry. The sidewall 42, forexample, may alternatively have an annular elongated, rectangular and/orirregular cross-sectional geometry. Furthermore, in some embodiments,the first fluid conduit 38 may include a protrusion (or anothersidewall) that provides the fluid flowpath 44 with an annular geometryas described below with reference to the second fluid conduit 40 (seeFIG. 4). The coupling assembly 36, of course, is not limited to theforegoing exemplary first fluid conduit 38 configurations.

Referring to FIG. 2, the second fluid conduit 40 may have a generallytubular outer sidewall 48 and an inner protrusion 50; e.g., a solidcylindrical object. The sidewall 48 and protrusion 50 are configured toform a fluid flowpath 52; e.g., an annular fluid flowpath. This fluidflowpath 52 extends along a centerline 54 through the second fluidconduit 40 and is fluidly coupled with the fluid flowpath 44.

Referring to FIG. 4, the sidewall 48 may have an annular circularcross-sectional geometry. The first fluid conduit 38, however, is notlimited to such a cross-sectional geometry. The sidewall 48, forexample, may alternatively have an annular elongated, rectangular and/orirregular cross-sectional geometry. Furthermore, in some embodiments,the second fluid conduit 40 may be configured without the protrusion 50,or the protrusion 50 may be replaced with an inner sidewall. Thecoupling assembly 36, of course, is not limited to the foregoingexemplary second fluid conduit 40 configurations.

The fluid conduits 38 and 40 are described above and illustrated in thedrawings with different configurations. In particular, the first fluidconduit 38 and the second fluid conduit 40 are configured withcross-sections of different shapes. A cross-sectional area of the fluidflowpath 44 is also different (e.g., smaller) than a cross-sectionalarea of the fluid flowpath 52. However, in other embodiments, the fluidconduits 38 and 40 may have substantially similar configurations.Furthermore, while the fluid conduits 38 and 40 are illustrated in thedrawings with non-parallel (e.g., perpendicular or otherwise angled)centerlines 46 and 54, in other embodiments the centerlines 46 and 54may be parallel and even co-axial.

Referring to FIG. 2, the first fluid conduit 38 is connected to thesecond fluid conduit 40. An end of the first fluid conduit 38, forexample, is connected to an end of the second fluid conduit 40. Thefirst fluid conduit 38 may be formed integral with the second fluidconduit 40 as illustrated in FIG. 2. Alternatively, referring to FIGS.5-7, the first and the second fluid conduits 38 and 40 may be formed asdiscrete (e.g., separate) units and subsequently attached to one anothervia a bonded connection (and/or a mechanical connection).

A joint 56 between the fluid conduits 38 and 40 may variousnon-interlocking and interlocking configurations. Examples of a jointwith a non-interlocking configuration include, but are not limited to, abeveled lap joint (see FIG. 5), a modified bridle joint (see FIG. 6), abutt joint and a shiplap joint. Examples of a joint with an interlockingconfiguration include, but are not limited to, a tabled splice joint(see FIG. 7) and a dovetail joint.

It is worth noting, a rectangular joint 58 as illustrated in FIG. 8 mayprovide a relatively abrupt transition between the fluid conduits 38 and40. Such an abrupt transition may cause fluid flow disturbances (e.g.,turbulence) and/or lead to formation of coke where the fluid flowingwithin the conduits 38 and 40 is heated fuel. In contrast, thenon-rectangular joint 56 embodiments of FIGS. 5-7 are configured toprovide a relatively gradual transition between the fluid conduits 38and 40. More particularly, fluid flowing between the fluid conduits 38and 40 progressively interacts with different portions of the joint 56.The gradual transition of the joint therefore may be useful in, amongother things, reducing fluid flow disturbances and/or reducing formationof coke where the fluid delivery system 20 is configured for deliveringfuel in a turbine engine. In addition, the joint 56 embodiments of FIGS.5-7 may be more durable than the joint 58 embodiment of FIG. 8.

A gap (or gaps) between the fluid conduits 38 and 40 may be filled withfiller material 60. Examples of filler material include, but are notlimited to, bonding material such as braze, weld and adhesive. Anotherexample of filler material is a seal; e.g., a metal or elastomeric seal.The filler material 60 may be operable to at least partially thermallydecouple the first fluid conduit 38 from the second fluid conduit 40.The filler material 60 may also or alternatively be operable to reducestress at the joint 56, 58 where, for example, the fluid conduits 38 and40 are subjected to opposing forces and/or moments.

FIG. 9 illustrates a hybrid joint 62 between the first fluid conduit 38and the second fluid conduit 40. In this embodiments, the first fluidconduit 38 is formed integral with the second fluid conduit 40 where abridge 64 integrally connects the conduits 38 and 40 together. Thisbridge 64 may be useful when forming the first and the second fluidconduits 38 and 40 using additive manufacturing. In contrast to theembodiment of FIG. 2, however, gaps extend between the fluid conduits 38and 40 that are filled with filler material 60 as described above. Thus,a seal between the fluid conduits 38 and 40 is provided by both fluidconduit 38, 40 material as well as the filler material 60 whereas theseal between the fluid conduits 38 and 40 of FIG. 2 may be providedsolely by the fluid conduit 38, 40 material.

The fluid conduits 38 and 40 may be substantially directly connectedtogether as illustrated in FIGS. 2 and 5-9. Alternatively, referring toFIGS. 10-12, the fluid conduits 38 and 40 may be indirectly connectedtogether through, for example, an intermediate fluid conduit 66. Thisintermediate fluid conduit 66 may be configured as a compliantintermediate fluid conduit. The intermediate fluid conduit 66, forexample, may be configured to flex thereby allowing “towards and away”movement, “side-to-side” movement and/or “twisting” movement between thefluid conduits 38 and 40. Thus, the intermediate fluid conduit 66 mayserve to reduce the transfer of forces and/or moments between the fluidconduits 38 and 40.

The intermediate fluid conduit 66 may be formed integral with the firstfluid conduit 38 and/or the second fluid conduit 40. The intermediatefluid conduit 66 may extend along a substantially straight centerline asillustrated in FIG. 10. Alternatively, the intermediate fluid conduit 66may extend along a curved centerline as illustrated in FIG. 11 and/or acompound centerline as illustrated in FIG. 12. The coupling assembly 36,however, is not limited to the exemplary intermediate fluid conduit 66configurations described above and illustrated in the drawings.

The coupling assembly 36 embodiments described above and illustrated inthe drawings may be manufactured using various processes. One or more ofthe coupling assembly components 38, 40, 64 and 66 may be formedintegral with one another; e.g., formed as a single unit. Alternativelyor in addition, one or more of the coupling assembly components 38, 40,64 and 66 may be formed discrete from one another; e.g., as physicallyseparate units. These discrete components may subsequently be assembledand attached to one another; e.g., mechanically fastened and/or bonded.

The coupling assembly components 38, 40, 64 and 66 are described aboveand illustrated in the drawings as having substantially constantcross-sectional geometries. For example, the shape and the size of thefirst fluid conduit 38 remains substantially constant as the conduit 38extends along its centerline 46. Similarly, the shape and the size ofthe second fluid conduit 40, the bridge 64 and the intermediate fluidconduit 66 remain substantially constant as these components 40, 64 and66 extend along their centerlines. In some embodiments, however, thecross-sectional geometries (e.g., the shapes and/or the sizes) of atleast a portion of one or more of the components 38, 40, 64 and 66 maychange as the respective components 40, 64 and 66 extend along theircenterlines. For example, the diameter of one or more the fluid conduits38 and 40 may decrease or increase as they extend towards the joint 56.The shape of one or more of the fluid conduits 38 and 40 may also oralternatively change at the joint 56 to provide a gradual transitiontherebetween. Of course, various other coupling assembly componentconfigurations are also possible and are intended to be within the scopeof the present disclosure.

The coupling assembly components 38, 40, 64 and 66 may be formeddiscretely and/or integral with one another using an additivemanufacturing process. The term “additive manufacturing” may describe aprocess where an additive manufacturing system builds up a part or partsin a layer-by-layer fashion. For example, for each layer, the additivemanufacturing system may spread and compact a layer of additivemanufacturing material (e.g., metal powder and/or non-metal powder) andsolidify one or more portions of this material layer with an energybeam; e.g., a laser beam or an electron beam. Examples of an additivemanufacturing system include, but are not limited to, a laser sinteringsystem, an electron beam system, a laser powder deposition system and anEB wire deposition system. Examples of metal(s) from which the couplingassembly 36 may be formed include, but are not limited to, nickel (Ni),titanium (Ti), steel, stainless steel, cobalt (Co), chromium (Cr),tungsten (W), molybdenum (Mo) and/or alloys including one or more of theforegoing metals such as Waspaloy, Stellite, etc. The coupling assemblycomponents, however, are not limited to being formed using additivemanufacturing or the foregoing metal materials. For example, one or moreof the coupling assembly components 38, 40, 64 and 66 may also oralternatively be formed using casting, machining, milling and/or anyother manufacturing process.

The fluid delivery system 20 of FIG. 1 may be configured with orincluded in various types of apparatuses and systems. The fluid deliverysystem 20, for example, may be configured in a fuel delivery system, alubrication system and/or a cooling or heating system of a turbineengine or any other type of engine. An example of such a turbine engine94 (e.g., a geared turbofan engine) is illustrated in FIG. 13.

The turbine engine 94 of FIG. 13 extends along an axial centerline 96between an upstream airflow inlet 98 and a downstream airflow exhaust100. The turbine engine 94 includes a fan section 102, a compressorsection 103, a combustor section 104 and a turbine section 105. Thecompressor section 103 includes a low pressure compressor (LPC) section103A and a high pressure compressor (HPC) section 103B. The turbinesection 105 includes a high pressure turbine (HPT) section 105A and alow pressure turbine (LPT) section 105B. The engine sections 102-105 arearranged sequentially along the centerline 96 within a housing 106.

Each of the engine sections 102-103B, 105A and 105B includes arespective rotor 108-112. Each of these rotors 108-112 includes aplurality of rotor blades arranged circumferentially around andconnected to one or more respective rotor disks. The rotor blades, forexample, may be formed integral with or mechanically fastened, welded,brazed, adhered and/or otherwise attached to the respective rotordisk(s).

The fan rotor 108 is connected to a gear train 114, for example, througha fan shaft 116. The gear train 114 and the LPC rotor 109 are connectedto and driven by the LPT rotor 112 through a low speed shaft 117. TheHPC rotor 110 is connected to and driven by the HPT rotor 111 through ahigh speed shaft 118. The shafts 116-118 are rotatably supported by aplurality of bearings 120; e.g., rolling element and/or thrust bearings.Each of these bearings 120 is connected to the engine housing 106 by atleast one stationary structure such as, for example, an annular supportstrut.

During operation, air enters the turbine engine 94 through the airflowinlet 98, and is directed through the fan section 102 and into a coregas path 122 and a bypass gas path 124. The air within the core gas path122 may be referred to as “core air”. The air within the bypass gas path124 may be referred to as “bypass air”. The core air is directed throughthe engine sections 103-105 and exits the turbine engine 94 through theairflow exhaust 100 to provide forward engine thrust. Within thecombustor section 104, fuel is injected into a combustion chamber andmixed with the core air. This fuel-core air mixture is ignited to powerthe turbine engine 94. The bypass air is directed through the bypass gaspath 124 and out of the turbine engine 94 through a bypass nozzle 126 toprovide additional forward engine thrust. Alternatively, at least someof the bypass air may be directed out of the turbine engine 94 through athrust reverser to provide reverse engine thrust.

The fluid delivery system 20 may be included in various turbine enginesother than the one described above. The fluid delivery system 20, forexample, may be included in a geared turbine engine where a gear trainconnects one or more shafts to one or more rotors in a fan section, acompressor section and/or any other engine section. Alternatively, thefluid delivery system 20 may be included in a turbine engine configuredwithout a gear train. The fluid delivery system 20 may be included in ageared or non-geared turbine engine configured with a single spool, withtwo spools (e.g., see FIG. 13), or with more than two spools. Theturbine engine may be configured as a turbofan engine, a turbojetengine, a propfan engine, or any other type of turbine engine. Thepresent invention therefore is not limited to any particular turbineengine types or configurations. Furthermore, while the fluid deliverysystem 20 is described above as being included in a turbine engine, thesystem may also be configured with various non-turbine engine systems;e.g., HVAC systems, automobile systems, etc.

While various embodiments of the present invention have been disclosed,it will be apparent to those of ordinary skill in the art that many moreembodiments and implementations are possible within the scope of theinvention. For example, the present invention as described hereinincludes several aspects and embodiments that include particularfeatures. Although these features may be described individually, it iswithin the scope of the present invention that some or all of thesefeatures may be combined with any one of the aspects and remain withinthe scope of the invention. Accordingly, the present invention is not tobe restricted except in light of the attached claims and theirequivalents.

What is claimed is:
 1. A method involving an additive manufacturingsystem, the method comprising: forming a first fluid conduit and asecond fluid conduit using the additive manufacturing system; andproviding a fluid coupling, the fluid coupling including the first fluidconduit and the second fluid conduit, the first fluid conduit connectedto and fluidly coupled with the second fluid conduit; and connecting andfluidly coupling the first fluid conduit to the second fluid conduitthrough a compliant intermediate fluid conduit that is formed integralwith the first and second fluid conduit; wherein the first fluid conduithas a first configuration, and the second fluid conduit has a secondconfiguration that is different than the first configuration.
 2. Themethod of claim 1, wherein the second fluid conduit is formed integralwith the first fluid conduit.
 3. The method of claim 2, wherein thefirst fluid conduit is connected to and fluidly coupled with the secondfluid conduit during the forming of the first and the second fluidconduits.
 4. The method of claim 2, further comprising fluidly couplingthe first fluid conduit to the second fluid conduit after the forming ofthe first and the second fluid conduits.
 5. The method of claim 1,wherein the first fluid conduit has a cross-section with a first shape;and the second fluid conduit has a cross-section with a second shapethat is different than the first shape.
 6. The method of claim 1,wherein the first fluid conduit forms a first flowpath with a firstcross-sectional area; and the second fluid conduit forms a secondflowpath with a second cross-sectional area that is different than thefirst cross-sectional area.
 7. The method of claim 1, wherein thecompliant intermediate fluid conduit is configured to flex therebyallowing towards and away movement, side-to-side movement and twistingmovement between the first fluid conduit and the second fluid conduit.8. The method of claim 1, wherein the compliant intermediate fluidconduit is configured to enable towards and away movement between thefirst fluid conduit and the second fluid conduit.
 9. The method of claim1, wherein the compliant intermediate fluid conduit is configured toenable side-to-side movement between the first fluid conduit and thesecond fluid conduit.
 10. The method of claim 1, wherein the compliantintermediate fluid conduit is configured to enable twisting movementbetween the first fluid conduit and the second fluid conduit.
 11. Themethod of claim 1, wherein the first fluid conduit, the second fluidconduit and the compliant intermediate fluid conduit each comprisingmetal.
 12. The method of claim 1, further comprising providing a nozzlefor a gas turbine engine fuel injector, the nozzle comprising the fluidcoupling.
 13. The method of claim 1, further comprising providing a fueldelivery system for a gas turbine engine, the fuel delivery systemcomprising the fluid coupling.
 14. The method of claim 1, furthercomprising providing a lubrication system for a gas turbine engine, thelubrication system comprising the fluid coupling.
 15. The method ofclaim 1, further comprising providing a cooling or heating system for agas turbine engine, the cooling or heating system comprising the fluidcoupling.